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Servomex 2700 Combustion Gas Analyser Installation Manual
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PROCESS ANALYSERS
SERVOTOUGH Fluegas (2700)
Gas Analyser
Installation Manual
Part Number:
Revision:
Language:
02700005C
3
UK English
This page intentionally blank
Servomex 2700
Combustion Gas Analyser
Installation Manual
Reference: 02700/005C/3
Order as part number: 02700005C
NOTES
TABLE OF CONTENTS
1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.1
1.2
1.3
1.4
1.5
2
SERVOMEX 2700 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
2.1
2.2
2.3
3
3.3
3.4
3.5
Installation location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Enclosure purge connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
INITIAL STARTUP PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
5.1
5.2
5.3
5.4
5.5
5.6
5.7
6
Installation location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Flange mounting arrangements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
3.2.1
Standard installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
3.2.2
Weld-on flange installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
3.2.3
Adaptor flange installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
3.2.4
High temperature stand-off installation . . . . . . . . . . . . . . . . . . . . . . .16
3.2.5
Thermal spacer installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
3.2.6
Probe retention flange installation . . . . . . . . . . . . . . . . . . . . . . . . . .20
Sample probe installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
3.3.1
Open-ended and unsupported filtered metal
probe installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
3.3.2
Open-ended ceramic probe installation . . . . . . . . . . . . . . . . . . . . . .22
3.3.3
Supported probe installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Calibration and utilities supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
INSTALLATION OF CONTROL UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
4.1
4.2
4.3
5
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Sensor head description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Control unit description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
INSTALLATION OF SENSOR HEAD AND PROBE TUBE. . . . . . . . . . . . . . . . . . . . . .9
3.1
3.2
4
Warnings, Cautions and Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Scope of this manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
General safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Hazardous Area approval and certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Gases required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Initial power up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Analogue output span setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Sensor head sample flow adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Combustibles sensor zero adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Sensor calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
MAINTENANCE AND SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Appendix A
INTERCONNECTING WIRING SCHEDULES. . . . . . . . . . . . . . . . . . . . . .51
Servomex 2700 Installation Manual
i
LIST OF FIGURES
Figure 1
Figure 2
Figure 3
Figure 4
Figure 5
Figure 6
Figure 7
Figure 8
Figure 9
Figure 10
Figure 11
Figure 12
Figure 13
Figure 14
Figure 15
Servomex 2700 sensor head and control unit overview . . . . . . . . . . . . . . .7
Servomex 2700 sensor head dimensions (typical) . . . . . . . . . . . . . . . . . .12
Adaptor flange installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
High temperature stand-off flange installation . . . . . . . . . . . . . . . . . . . . . .17
Thermal spacer installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Probe retention flange installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Sample probe and filter construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Supported probe construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Probe support tube installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Sensor head terminal enclosure detail. . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Control unit installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Control unit enclosure detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Oxygen sensor only interconnection wiring schematic . . . . . . . . . . . . . . .52
Combustibles only interconnection wiring schematic . . . . . . . . . . . . . . . .54
Dual sensor interconnection wiring schematic . . . . . . . . . . . . . . . . . . . . .56
LIST OF TABLES
Table 1
Table 2
Table 3
Table 4
Table 5
Table 6
Table 7
Table 8
Table 9
Table 10
Table 11
Table 12
Table 13
Table 14
Table 15
ii
Sensor head operating environment . . . . . . . . . . . . . . . . . . . . . . .
Sensor head adaptor flange kits. . . . . . . . . . . . . . . . . . . . . . . . . . .
Sample probe part numbers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sensor head electrical power connections. . . . . . . . . . . . . . . . . . .
Control unit operating environment . . . . . . . . . . . . . . . . . . . . . . . .
Control unit electrical power voltage selection . . . . . . . . . . . . . . . .
Control unit electrical power connections. . . . . . . . . . . . . . . . . . . .
Relay output connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Analogue output connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
User remote dry contact inputs . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gas requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Interconnecting cable requirements . . . . . . . . . . . . . . . . . . . . . . . .
Oxygen sensor only interconnecting wiring . . . . . . . . . . . . . . . . . .
Combustibles only interconnecting wiring . . . . . . . . . . . . . . . . . . .
Dual sensor interconnecting wiring . . . . . . . . . . . . . . . . . . . . . . . .
Servomex 2700 Installation Manual
10
14
23
31
36
39
42
42
43
43
45
51
53
55
57
1
INTRODUCTION
1.1
Warnings, Cautions and Notes
This manual includes WARNINGS, CAUTIONS and NOTES which provide
information relating to the following:
WARNINGS
Hazards which could result in personal injury or death
CAUTIONS
Hazards which could result in damage to equipment or property
NOTES
Alert the user to pertinent facts and conditions
CAUTION – refer to the Installation Manual
1.2
Scope of this manual
This manual covers the installation of the Servomex 2700 Combustion Gas Analyser
and the various options that are available.
•
Refer to the QuickStart Manual or Technical Data Sheet for latest technical
specification.
•
Addresses for technical assistance and spares are given on the rear cover.
•
A QuickStart Manual is available, part number 02700003C.
•
A Service Manual is available for use by qualified personnel, part number
02700002C.
About this manual
Reference: 02700/005C/3
Order as part number: 02700005C
Servomex 2700 Installation Manual
1
CE Marking
The Servomex 2700 analyser carries the CE mark which indicates conformity with
the European Community Directives on CE Marking (93/68/EEC), Electromagnetic
Compatibility (EMC 89/336/EEC) and Low Voltage Directive (LVD 73/23/EEC).
Servomex 2700 control units are marked in conformity with the Explosive
Atmospheres (ATEX) Directive (94/9/EC) when fitted with a European hazardous
area certification marking plate.
2
Servomex 2700 Installation Manual
1.3
General safety information
Specific standards of safety are not included in this manual, since requirements of
relevant authorities vary widely. The safety precautions described in the following
installation instructions ensure that the existing safety features are not impaired
during installation. The precautions do not guarantee a safe installation if other
relevant safety codes are ignored.
WARNING
•
The electrical power used in this equipment is at a voltage high enough to
endanger life.
•
It is essential that only suitably trained and competent personnel are allowed
to access hazardous live parts by removing or opening covers of the
analyser.
•
The sensor head is heated and may be attached to a hot flue. The external
surfaces will be uncomfortably hot even after power down for several hours.
Exercise care when handling the sensor head even when un-powered on a
hot flue.
•
The installer must be satisfied that the Servomex 2700 installation conforms
to the relevant safety requirements, National Electrical Code and any other
local regulations and that the installation is safe for any extremes of
conditions which may be experienced in the operating environment of the
analyser.
•
This appliance must be connected to a protective earth.
•
The electrical installation must include a means of isolating electrical power
by a switch or circuit breaker external to the analyser and within easy reach
of the operator. It must be marked as the disconnecting device for the
equipment.
•
To comply with the European Community EMC Directives for industrial
environments the interconnecting cables, mains supply, relay contact outputs
and/or analogue output signals should be screened or provide equivalent
protection.
•
The Servomex 2700 sensor head aspirator supply is suitable for use with
compressed air only. Flammable gases must not be used for the aspirator
supply.
•
The Servomex 2700 sensor head is not suitable for use in hazardous areas /
locations without the use of appropriate safety purge equipment.
•
Servomex 2700 EU2/UK2/FM2/CS2 approved control units must be used if
the installation is in a Category 3/Zone 2/Division 2 hazardous area/location.
•
Flanges and flange adaptors supplied by Servomex DO NOT conform to
ANSI or any other Standards body and must only be used in Servomex
specified applications with process pressure not greater than 5psig.
Servomex 2700 Installation Manual
3
NOTE
The branch circuit supplying power to this instrument should be installed with a
suitable fuse rated not greater than 15A or a suitable over-current protection device
set not greater than 15A.
1.4
Hazardous Area approval and certification
Copies of all hazardous area certificates are provided in the Certificate Manual
(part number 02700008C) which is supplied with each hazardous area certified unit.
In summary, the Servomex 2710 control unit is certified for use in Category 3/Zone 2/
Division 2 areas (for both gas and dust hazards) and is available with the following
hazardous area approvals:
Europe
Approved as Ex ic nA nC IIC T5 Gc, Ex tc IIIB T75°C Dc (Ta = -10°C to +55°C) for
ATEX Group II, Category 3, Gas and Dust hazardous atmospheres.
ITS10ATEX47005X. In addition the serial number and year of manufacture are
marked on an external rating plate.
United States
Factory Mutual approved as non-incendive for:
Class I, Div. 2, Groups A,B,C & D.
Class II, Div. 2, Groups F & G.
Class III, Div. 1 & 2.
Enclosure Type 4X.
T5. Ambient Temperature 55°C max.
Canada
CSA: suitable for use in:
Class I, Div. 2, Groups A,B,C & D.
Class II, Div. 1, Groups E,F & G.
Class III, Div. 1.
Enclosure Type 4X.
T5. Ambient Temperature 55°C max.
WARNING
To minimise the risk of propagating brushed discharges, do not install in a high
velocity dust laden environment.
4
Servomex 2700 Installation Manual
1.5
Unpacking
WARNING
The Servomex 2700 sensor head and control unit weigh approximately 17Kg
(37.5lb) and 11Kg (24.3lb) respectively and care must be taken when handling.
•
Remove the Servomex 2700 components from their packing and inspect for
obvious external damage.
•
If damage has occurred, inform Servomex or its agent immediately.
Retain all packing and shipping information for future use.
Servomex 2700 Installation Manual
5
This page is intentionally blank
6
Servomex 2700 Installation Manual
2
SERVOMEX 2700 OVERVIEW
2.1
Overview
Figure 1
Servomex 2700 sensor head and control unit overview
3
6
7
Control Unit
2
8
5
Sensor Head
1
4
10
9
Key to Figure 1 – Servomex 2700 sensor head and control unit
overview
1
Terminal enclosure cover
6
Sample probe
2
Sensor head cover
7
Sample probe filter
3
4" mounting flange
8
Control unit
4
4" weld-on flange
9
Wall mounting brackets
5
Flue/process wall
10
Keypad and display
Servomex 2700 Installation Manual
7
The Servomex 2700 Combustion Gas Analyser measures combustion and similar
gases to provide an analysis of the oxygen concentration and/or the level of unburned
combustibles. The analyser comprises two separate units which may be mounted up
to 300m (975ft) apart for oxygen only and 100m (325ft) apart whenever the
combustibles measurement option is fitted.
An overall system will consist of sensor head/sample probe/filter mounted directly
onto the flue wall and a control unit mounted remotely from the sensor head. The user
must ensure that both the sensor head and control unit have their own separate
power supply. Also required is a compressed air supply with a pressure regulator to
control the aspirator air supply.
An optional utilities unit is available to supply the sensor head with calibration gases
and compressed air.
2.2
Sensor head description
The sensor head is flange mounted on to the flue wall and houses the measurement
sensors in a heated enclosure. A probe tube projects through the duct wall into the
process gas to extract a gas sample for analysis. A comprehensive range of sample
probes and filters are available to enable the analyser to be used in a wide range of
applications and process conditions. Electrical connections are made to a terminal
box located on the side of the sensor head.
2.3
Control unit description
The control unit houses the drive electronics, microprocessor, keypad, display and
user wiring connections. The control unit may be either wall, surface or panel
mounted. Electrical connections are made via conduit entries located on the bottom
of the control unit enclosure.
8
Servomex 2700 Installation Manual
3
INSTALLATION OF SENSOR HEAD AND PROBE TUBE
3.1
Installation location
Refer to Figure 2.
NOTE
All Servomex adaptor flanges, interface flanges, probe support tubes, stand-offs
and thermal spacers, including the integral flange on the sensor head, are suitable
for fitting onto the standard flanges (raised face [<1.6mm] or flat faced). They do not
comply with any national or international standards and the analyser’s maximum
process pressure is limited to 5psig.
Select a location which allows convenient access for installation and maintenance to
the terminal box enclosure. The sensor head is supplied with a 4" flange for direct
attachment to a flue wall.
The Sensor Head may be mounted in any orientation, except with the terminals box
directly above the sensor enclosure or with the mounting flange facing directly
upwards.
Ensure that the operating ambient
temperature is in the range of −20°C to
+70°C and that the Sensor Head is
protected from radiant heat sources or
from direct sunlight (in ambient
Temperatures over 30°C). This can be
achieved by installing a Heat Shield
between the Sensor Head and the
source; a thin metal sheet is usually
adequate.
Heat Shield
Radiating
Heat
Source
Sensor
Head
Operating environment conditions for the sensor head are given in Table 1
Servomex 2700 Installation Manual
9
Table 1 – Sensor head operating environment
Item
Specification
Ambient operating
temperature
-20°C to +70°C (-4°F to +158°F)
Storage temperature
-30°C to +80°C (-22°F to +176°F)
Ingress protection
IP66 and NEMA 4X
AC power supply
Factory set for either
a) 100-120Vac 50/60Hz
b) 220-240Vac 50/60Hz
a) 100-120Vac -15% +10%
(Min. 85V – Max. 132V)
b) 220-240Vac -15% +10%
(Min. 187V – Max. 264V)
Altitude
Up to 2000m
Installation category
Category II. Local level power distribution with
over-voltage withstand up to 2500V (in
accordance with IEC 664).
Pollution degree
The sensor head/terminal box is rated Pollution
Degree 2 (in accordance with IEC 664 ).
The sample probe protruding into the flue and
the adjacent face of the flange is rated Pollution
Degree 4 (in accordance with IEC 664 ).
See Note 1
Relative humidity
0 to 80% RH
Note 1: Where the installation is such that the enclosure ingress protection
IP66/Type 4X is maintained and the covers remain securely fitted, the apparatus
is suitable for use in locations where there may be significant deposits of
nonflammable dusts or fibres (Pollution Degree 4) and/or where there may be
drips, splashes of water, prolonged exposure to rain or subjected to hose down.
The covers may be removed during installation or servicing only if there is
negligible risk of pollution or contamination of the electronic circuits contained
within the enclosures and if the covers are securely replaced immediately after
the operation is completed. Refer to Section 6.
10
Servomex 2700 Installation Manual
.
CAUTIONS
•
Do not lift the sensor head by the compressed air pipe that is connected
between the solenoid valve and the bulkhead fitting.
•
The anti-seize compound (part number 1761-3211) and ROCOL ASP dry
film anti-scuffing paste are the only recommended release compounds. The
use of "Silver Goop" or other similar release agents may result in permanent
damage to the combustibles sensor (if fitted).
Servomex 2700 Installation Manual
11
Figure 2
Servomex 2700 sensor head dimensions (typical)
131mm
2
125mm
19mm
18mm
1
This dimension depends
on gland type fitted
3
142mm
40mm 40mm
301mm
143mm
9
85mm
9mm
330mm
55mm 55mm 55mm
117mm
115mm
115mm
10
188mm
4
123mm
131mm
138mm
8
11
7
5
6
Key to Figure 2 – Servomex 2700 sensor head dimensions
12
1
Analyser mounting flange 4"
2
Sample vent port 1/8" NPT (INT)
3
Sample probe connection 1/2" NPT (INT)
4
Calibration gas inlet 1/4" OD compression fitting
5
Purge gas exit, 1/4" NPT (INT), or breather fitting
6
Unused Entry
7
Purge gas entry, 1/4" NPT (INT) or blanking plug
8
Signal cable entry 3/4" NPT (INT) or specified adaptor
9
Mains cable entry 3/4" NPT (INT) or specified adaptor
10
Aspirator air supply inlet 1/8" NPT (INT)
11
M6 screws (4 off)
Servomex 2700 Installation Manual
3.2
Flange mounting arrangements
CAUTION
The user should ensure that the flue wall is strong enough to support the weight of
the sensor head and sample probe tube.
•
SPECIAL INSULATION NOTES
When a length of stand-off tube is used to secure the mounting flange to the
flue it should be insulated efficiently to prevent problems occurring due to
excessive heat loss to the atmosphere.
•
Always minimise the length of this stand-off tube (<100mm typical).
NOTES
•
Ensure that mounting bolts are tightened evenly to prevent the sensor head
from tilting, damaging the gasket and causing leaks.
•
The sensor head must not be left un-powered when mounted on an active
flue. If the sensor head is not to be fitted immediately then a blanking flange
should be used. Do not plug the hole with the sensor head.
•
Included in the installation kit is a sachet of anti-seize compound (part
number 1761-3211) to be used on the sensor head mounting bolts and
studs. Failure to use the anti-seize compound may make the fittings difficult
to remove.
3.2.1 Standard installation
The sensor head is provided with a 4" flange. The flange has 8 off 19mm diameter
holes at 45° intervals on a 190.5mm diameter pitch circle (PCD). The sensor head
should be mounted to the flue with at least four M16 or 5/8" bolts or studs spaced
equally around the flange. The sensor head can be mounted to an existing 4" ANSI
150 flange, a weld-on ANSI flange (see Section 3.2.2) or to an existing flange of
another type (see Section 3.2.3). Thermal spacers, high temperature stand-offs and
probe retention flange options are also available for extreme environments. The
length of the mounting bolts required will depend on the mounting options selected.
For installation on an existing 4" ANSI flange provided with clearance rather than
threaded holes then at least four M16x65mm or 5/8"x2½" bolts will be required. The
sensor head will be provided with sufficient gaskets, M16 studding and M16 nuts and
washers to mount the sensor head configuration supplied onto a Servomex weld on
4" flange.
Servomex 2700 Installation Manual
13
3.2.2 Weld-on flange installation
If there is no existing flange available then a weld-on flange (part number 02750409)
may be provided. The square (250mm x 250mm) weld-on flange is provided with 8 off
M16 threaded holes at 45° intervals on a 190.5mm diameter pitch circle. Cut a hole
102mm (4 inches) to 127mm (5 inches) diameter in the wall of the duct and weld-on
the flange. If no further mounting options have been ordered then screw the 4 off
M16x55mm studs provided into alternate holes on the flange (at 90° intervals). Place
the gasket over the locating studs, mount the sample probe onto the sensor head
(see Section 3.3), and secure the sensor head onto the flange with the 4 off M16 nuts
and washers.
3.2.3 Adaptor flange installation
A variety of adaptor flange kits are available (see Table 2) for fitting to flanges other
than 4" ANSI 150. The flange on the process duct should be supplied with clearance
holes appropriate to the flange type.
Refer to Figure 3.
Screw the flue mounting studs [8] and the four M16x55mm studs [7] into the
appropriate threaded holes on the adaptor flange [3]. Ensure that the studs do not
protrude through the flange as this will cause damage to the gasket/s and could
cause leaks. Mount the adaptor flange [3] to the flue mounting flange [1] using the
appropriate gasket [2] and secure with the nuts and washers [9] from the reverse.
Attach the sample probe to the sensor head (see Section 3.3). Mount the 2700 sensor
head [5] to the adaptor flange [3] using the 4" ANSI sealing gasket [4] and the 4 off
M16 nuts and washers [6].
Table 2 – Sensor head adaptor flange kits
Mating Pattern
Servomex
Kit No.
Mtg.hole
Qty
PCD
Mates With
02750992
10.8 dia
8
120.6
Servomex Model 700B /N
02750991
M16
4
152.4
3" ANSI 150
02750991
M16
4
145.0
DIN 65 PN16
02750991
M16
4
145.0
JIS 80 5Kg/cm2
02750990
M12
4
130.0
DIN 80 PN16
02750989
M12
4
130
02750988
M16
4
168.3
02750991
18.0 dia
c/bored 38.0
dia
14
JIS 65 5Kg/cm2
3" ANSI 300
Thermox WDG IV
3
168.3
Servomex 2700 Installation Manual
Figure 3
Adaptor flange installation
1
3
2
4
5
9
8
7
6
Key to Figure 3 – Adaptor flange installation
1
Mounting flange on flue
2
Gasket to suit flue mounting flange
3
Adaptor flange to suit flue mounting flange (see Table 2)
4
ANSI 4" gasket
5
4" flange on 2700 sensor head
6
M16 nuts and washers (4 off each)
7
M16 by 55mm studs (4 off)
8
Studs (type and length specific to flue mounting flange)
9
Nuts and washers (number and size to suit flue mounting flange)
Servomex 2700 Installation Manual
15
3.2.4 High temperature stand-off installation
Where there may be excessive heat radiated from the flue wall (350°C to 500°C), a
high temperature stand-off flange kit (part number 02750995) is available to prevent
overheating of the sensor head. The high temperature stand-off is also available with
a probe retention flange (part number 02750996). The high temperature stand-off
consists of two 4" flanges welded onto a 102mm (4 inch) diameter pipe. Each of the
flanges has four M16 threaded and four 19mm plain holes equally spaced on a
190.5mm diameter pitch circle (PCD).
Refer to Figure 4.
•
Where necessary fit the weld-on flange or adaptor flanges as described in
Sections 3.2.2 and 3.2.3.
•
Mount the high temperature stand-off [3] onto the flue using a 4" ANSI sealing
gasket [2]. If a 4" ANSI weld-on, or adaptor flange, is already fitted then screw
in four of the M16x55mm studs [9] into alternate holes in the weld-on or
adaptor flange [1] and attach the high temperature stand-off through the four
plain holes in the stand-off flange. If the high temperature stand-off is to be
attached to an existing 4" ANSI flange then use four M16x65mm (or 5/8"x2½")
bolts at 90° intervals through the plain holes in the flange (bolts not supplied).
•
If a probe retention flange is not required then mount the sample probe onto
the sensor head (see Section 3.3). Mount the sensor head onto the high
temperature stand-off using a 4" ANSI sealing gasket [4]. Screw the four
M16x55 studs [7] into the threaded holes in the stand-off flange and secure the
sensor head with the four M16 nuts and washers [6].
•
If a probe retention flange is to be installed then screw the M16x80mm studs
supplied into the threaded holes in the stand-off flange and install the probe
retention flange as described in Section 3.2.6.
16
Servomex 2700 Installation Manual
Figure 4
High temperature stand-off flange installation
1
9
8
2
3
7
4
5
6
Key to Figure 4 – High temperature stand-off flange installation
1
4" ANSI flange on flue with weld-on or adaptor flange fitted
where necessary
2
ANSI 4" gasket
3
High temperature stand-off
4
ANSI 4" gasket
5
4" flange on 2700 sensor head
6
M16 nuts and washers (4 off each)
7
M16 by 55mm studs (4 off)
8
M16 nuts and washers (4 off)
9
M16 by 55mm studs (4 off)
Servomex 2700 Installation Manual
17
3.2.5 Thermal spacer installation
When the flue surface temperature is between 350°C and 500°C, a thermal spacer
(part number 02750997) is available to prevent overheating the sensor head. The
thermal spacer is also available with a probe retention flange (part number 02750996).
The spacer is provided with eight 19mm diameter holes equally spaced on a
190.5mm diameter pitch circle (PCD).
Refer to Figure 5.
•
Where necessary fit the weld-on flange or adaptor flange as described in
Sections 3.2.2 and 3.2.3.
•
If a weld-on flange or adaptor flange has been fitted then screw the four
M16x80mm studs [7] into alternate threaded holes in the flange. Mount the
thermal spacer [3] with a 4" sealing gasket at each side [2 and 6]. Mount the
sample probe onto the sensor head (see Section 3.3). Secure the sensor head
flange [4] to the thermal spacer with the four M16 nuts and washers [5].
•
If a weld-on or adaptor flange is not fitted then replace the four M16x80mm
studs with M16x100mm or 5/8"x4" bolts (not supplied).
•
Identify and mark the correct orientation of the retention flange so that the
sample vent hole in the flange will align with the vent hole on the sensor head
when installed in its desired orientation on the flue.
•
If a probe retention flange is to be installed then replace the M16x80mm studs
with the M16x105mm studs supplied. Install the probe retention flange as
described in Section 3.2.6.
18
Servomex 2700 Installation Manual
Figure 5
Thermal spacer installation
2
1
7
6
3
4
5
Key to Figure 5 – Thermal spacer installation
1
Mounting flange on flue. Adaptor flange fitted where necessary
to provide 4" ANSI 150lb flange
2
ANSI 4" gasket
3
Insulation flange
4
4" flange on Servomex 2700 sensor head
5
M16 nuts and washers (4 off each)
6
ANSI 4" gasket
7
M16 by 80mm studs (4 off)
Servomex 2700 Installation Manual
19
3.2.6 Probe retention flange installation
A probe retention flange (part number 02750998) is available when it is required to
leave the probe in the process during servicing. This is useful when used in
conjunction with a ceramic probe, so as to prevent the possibility of it being damaged
during extraction. The probe retention flange is also available in conjunction with the
thermal spacer and high temperature stand-off mounting options.
Refer to Figure 6.
•
Where necessary fit the weld-on flange, adaptor flange, high temperature
stand-off or thermal spacer as described in Sections 3.2.2, 3.2.3, 3.2.4 or
3.2.5.
•
Identify and mark the correct orientation of the retention flange so that the
sample vent hole in the flange will align with the vent hole on the sensor head
when installed in its desired orientation on the flue.
•
Attach the ceramic probe to the probe retention flange as detailed in
Section 3.3.2.
•
If the probe retention flange is being attached to a weld-on flange or adaptor
flange [1] then screw the four M16x80mm studs [2] into alternate threaded
holes in the weld-on or adaptor flange. Fit the 4" sealing gasket [4] over the
protruding studs [2]. Then carefully insert the ceramic probe and retention
flange through the hole in the centre of the flange/s and secure with the four
M16 half nuts and washers [6]. If a weld-on or adaptor flange is not fitted then
replace the four M16x80mm studs with M16x100mm bolts (not supplied).
•
If the probe retention flange is being attached to a high temperature stand-off
then insert the ceramic probe carefully through the hole in the high
temperature stand-off and secure the probe retention flange onto the four
M16x80mm studs with a 4" ANSI sealing gasket and the four M16 half nuts
and washers.
•
If the probe retention flange is being attached to a thermal spacer then insert
the ceramic probe carefully through the hole in the thermal spacer and secure
the probe retention flange onto the four M16x105mm studs with a 4" sealing
gasket and the four M16 half nuts and washers.
•
Mount the sensor head onto the protruding part of the mounting studs using
the 4" ANSI sealing gasket [7] and the four M16 nuts and washers [8]
provided. Ensure that the vent hole in the gasket and in the retention flange
are aligned with the sample vent on the sensor head.
20
Servomex 2700 Installation Manual
Figure 6
Probe retention flange installation
4
2
1
3
5
6
7
8
Key to Figure 6 – Probe retention flange installation
1
Adaptor flange
2
4 x M16x80mm studs
3
Ceramic probe
4
4" sealing gasket (large central hole)
5
Probe retention flange
6
4 x M16 half nuts and washers
7
4" ANSI sealing gasket
8
4 x M16 nuts and washers
Servomex 2700 Installation Manual
21
3.3
Sample probe installation
CAUTION
If the flue is brick lined, ensure that the full diameter of the probe hole is maintained
through the brickwork and is in line with the flange.
There are many possible configurations for the probe assemblies grouped into three
main types:
•
Open-ended sample probes (only use with internal sample filter option).
•
Unsupported filtered sample probes.
•
Supported filtered sample probes.
Table 3 contains a list of the different sample probes available and their part numbers.
The installation of the different sample probe types is detailed in the following
sections.
3.3.1 Open-ended and unsupported filtered metal probe installation
The open-ended and unsupported filter probes are available in 4 different lengths and
2 different materials depending on process conditions and flue temperature. Refer to
Figure 7 for construction of the filter probe.
•
Cut the probe tube to length if required. The cut should be square and any
burrs and swarf should be removed.
•
Fit the tube coupling to the sensor head sealing the thread with PTFE tape.
•
Fit the probe tube into the coupling until the probe tube bottoms out in the
sensor head. Swage the coupling ferrule onto the tube by tightening the
coupling finger tight plus a further 3/4 to 1 turn.
•
Insert the probe carefully through the hole in the flange gasket and attach the
sensor head onto the flue. Ensure that the mounting bolts are tightened evenly.
3.3.2 Open-ended ceramic probe installation
The open-ended ceramic probe is available in three different lengths. The probe is
supplied complete with a ½" NPT threaded stainless steel fitting bonded to the end of
the ceramic tube. The ceramic probe may be attached directly to the sensor head
(using PTFE tape to seal the thread) or to a probe retention flange. The probe
retention flange is used to avoid potential damage to the fragile probe when removing
the sensor head from the flue for maintenance purposes. Refer to Section 3.2.6 for
probe retention flange installation.
22
Servomex 2700 Installation Manual
Table 3 – Sample probe part numbers
0.5m
1.0m
1.5m
2.0m
2.5m
3.0m
Open-ended, Stainless Steel, <700°C
S2740701A
S2740701B
S2740701C
NA
NA
NA
Open-ended, High temperature alloy, <1000°C
S2740704A
S2740704B
NA
NA
NA
NA
Open-ended, High temperature alloy, <800°C
S2740704A
S2740704B
S2740704C
NA
NA
NA
Open-ended, High temperature alloy, <700°C
S2740704A
S2740704B
S2740704C
S2740704D
NA
NA
NA
NA
Filtered, Stainless Steel, <700°C
S2740702A
S2740702B
S2740702C
NA
Filtered, High temperature alloy, <1000°C
S2740705A
S2740705B
NA
NA
NA
NA
Supported filtered, Stainless Steel, <700°C
NA
NA
S2740703C
S2740703D
S2740703E
S2740703F
Open-ended ceramic, <1750°C
02740707A
02740707B
02740707C
NA
Servomex 2700 Installation Manual
NA
NA
23
Figure 7
Sample probe and filter construction
2
1
4
6
3
11
10
9
8
7
5
Key to Figure 7 – Sample probe and filter construction
24
1
Fibre sealing washer
2
Fibre sealing washer
3
½" NPT threaded mounting hole in Servomex 2700 filter block
4
2700 mounting flange
5
Mounting flange on flue
6
½" compression to ½" NPT adaptor
7
Probe tube
8
Filter retaining cap
9
Silicon carbide filter element
10
Filter retaining cap
11
Locking nut assembly
Servomex 2700 Installation Manual
Figure 8
Supported probe construction
3
1
20 ±2
4
7
A
45 ±2
2
6
5
11
Direction Of
Sample Flow
A
8
9
10
Key to Figure 8 – Supported probe construction
1
Silicon carbide sample filter
2
Sample filter shroud (V deflector)
3
Sample filter shroud M8x18mm fixing screw
4
Sample filter shroud collar
5
Sample probe retaining disc
6
Sample probe retaining disc M5x10mm fixing screws (2 off)
7
Support tube
8
4" sealing gasket
9
Support tube flange
10
4 x M16 nuts and washers
11
Sample probe tube
Servomex 2700 Installation Manual
25
3.3.3 Supported probe installation
The supported probe assembly are supplied in a range of lengths from 1.5m to 3.0m
in 0.5m steps. The installation process may be divided into three parts.
Cutting the probe and support tubes to length
•
The probes are provided cut to the correct lengths for the nominal specified
insertion depth. To shorten the probe assembly cut equal lengths from both the
support tube and the probe tube. The cuts should be square and any burrs and
swarf removed.
Installing the support tube assembly
•
Refer to Figure 8. Fit the sample filter shroud [2] onto the end of the support
tube [7]. The sample filter shroud [2] must be positioned with respect to the
direction of the sample flow as shown in Figure 8. The end of the sample filter
shroud collar [4] must be flush with the end of the support tube [7]. The
M8x18mm hex head shroud fixing screw [3] should then be tightened to
securely locate the sample filter shroud [2] in position. Mark the support tube
flange [9] to identify the orientation of the shroud and the direction of the
sample flow.
•
Refer to Figure 9. Where necessary fit the weld-on flange or adaptor flange, as
described in Sections 3.2.2 or 3.2.3. If the support tube flange is being
attached to a weld-on flange or adaptor flange then screw the four M16x80mm
studs into alternate threaded holes in the weld-on or adaptor flange. Secure
the support tube flange with a 4" sealing gasket and the four M16 half nuts and
washers. If a weld-on or adaptor flange is not fitted then replace the four
M16x80mm studs with M16x100mm bolts (not supplied). Ensure the filter
shroud orientation is correct with respect to the direction of sample flow in the
process.
Installing the filter probe assembly
•
Refer to Figure 8. Fit the probe retaining disc [5] onto the sample probe
tube [11]. Fix in position using the two M5x10mm grub screws [6]. The front
face of the disc should be positioned approximately 20mm from the back face
of the filter assembly.
•
Fit the tube coupling to the sensor head sealing the thread with PTFE tape.
•
Fit the probe tube into the coupling until the probe tube bottoms out in the
sensor head. Swage the coupling ferrule onto the tube by tightening the
coupling finger tight plus a further 3/4 to 1 turn. Release the union nut from the
fitting in the sensor head.
•
Insert the sample probe into the probe support tube. Taking care to leave at
least 100mm protruding from the flange to allow attachment to the sensor
head.
•
Fit a 4" sealing gasket [7] over the protruding studs from the support tube
flange.
•
Attach the sensor head to the protruding length of the sample probe tube using
the compression fitting. Attach the sensor head to the support tube flange and
secure in place with the four M16 nuts and washers [8].
26
Servomex 2700 Installation Manual
Figure 9
Probe support tube installation
2
1
7
3
6
4
5
Key to Figure 9 – Probe support tube installation
1
Mounting flange on flue. Adaptor flange fitted where necessary
to provide 4" ANSI 150 lb flange.
2
ANSI 4" gasket
3
Support tube flange
4
4" flange on 2700 sensor head
5
M16 nuts and washers (4 off each)
6
ANSI 4" gasket
7
M16 by 80mm studs
Servomex 2700 Installation Manual
27
3.4
Calibration and utilities supplies
Refer to Figure 2.
WARNING
The maximum pressure that should be applied to any of the Servomex 2700
analyser inlet ports is 1 bar (max).
A number of calibration and utilities gas supplies are required by the sensor head
depending on the sensor configuration used. For optimum preformance, only one
analyser should be used in conjunction with an air supply or utilities unit.
All pressure regulators, flow meters and gauges exhibit variations of output with
changes in ambient temperature. Care should be taken to choose products with either
a good rejection to changes in ambient temerature or to install air supply units in
stable ambient conditions.
Aspirator supply
The aspirator air supply is used to extract the sample from
the flue and is required for all sensor head configurations.
This is an instrument grade compressed air supply
provided to a 1/8" NPT (internal) threaded port (item 10) on
the solenoid valve body. The compressed air supply should
be clean, dry, free from oil and dirt ideally conforming to
ISA-S7.0.01 1996. The aspirator pressure range required
is 3 to 5psig (0.2 to 0.3barg). The flow rate is typically
1.5l/min under typical flue pressure conditions.
Calibration gas
Required for all sensor head configurations. Calibration
gas is supplied to the sensor head via a 1/4" OD
compression fitting (item 4).
The calibration gas supply pressure should be regulated
externally to give a flow rate to the port of
600ml/min ±20ml/min.
Purge supply
Optional feature. Where required, the purge gas must be
air from a non-hazardous area source. The purge air
fittings are threaded 1/4" NPT (internal). The purge inlet is
to the terminal box (item 7) and the vent is on the sensor
head body (item 5). The supply should be clean, dry, free
from oil and dirt ideally conforming to ISA-S7.0.01-1996
and the pressure should be regulated externally.
For hazardous Areas, the purge must satisfy the area
safety requirements.
For corrosive purge, a flow rate of 50 to 100ml/min at 50 to
100mm H2O is required.
28
Servomex 2700 Installation Manual
CAUTION
If the optional sensor head purge fittings are used then ensure that the purge gas
entry and vent fittings are the correct way round. Providing the purge gas inlet to
the sensor head body rather than the terminal box will result in overheating of the
terminal box PCB.
Blowback
Should be supplied at a pressure no greater than 15psig
(105kPag).
Blow back must not be used instead of a suitably specified
sample probe. If you have any concerns over the included
probe, consult Servomex prior to installation.
Auto Calibration
Time must be given to allow for calibration pipe work to be
flushed and for the sensors to stabilise. This depends on
the separation between gas supply point and the Sensor
Head.
Servomex 2700 Installation Manual
29
3.5
Electrical installation
WARNINGS
Refer to the warnings and conditions outlined in the "General safety information" in
Section 1.3 of this manual.
CAUTION
•
The sensor head supply voltage is factory set for either 100-120V or
220-240V (nominal). This is not field adjustable.
•
Ensure that the rated voltage is suitable for the installation.
•
Ensure that the link on the terminal PCB has been set to the correct supply
voltage. Refer to Figure 10. The supply voltage is set by linking together the
terminals at terminal block TB9. For 220-240V operation link together
terminals TB9/2 and TB9/1. For 110-120V operation link together terminals
TB9/2 and TB9/3. For 100V operation link together terminals TB9/2 and
TB9/4.
•
Use wires suitable for 30°C above surrounding ambient.
•
The sensor head is intended to be powered from a supply which has the
'Neutral' conductor referenced to ground. Where this is unavailable, it is
recommended that a suitable isolating transformer is installed and the
secondary winding is referenced to ground.
Alternatively, the electrical installation must include a fuse rated
"F 6.3A HRC" in each supply conductor. The disconnect device (see also
Section 1.3) must disconnect each supply conductor. The fuses must be
marked as being associated with this equipment. Ensure that the installation
conforms to the relevant national and local safety requirements.
30
Servomex 2700 Installation Manual
NOTES
•
The sensor head and control unit have independent electrical supplies.
•
If applicable the conduit or screen associated with the power supply should
be grounded at the cable gland or conduit entry to the sensor head terminal
enclosure in accordance with local wiring regulations.
•
In order to avoid ground loops, it is recommended that cable screens
associated with the signal cable(s) connecting the control unit and sensor
head do not terminate directly to ground at the sensor head. The screens
should be terminated to TB5/13, TB3/9 and the stud PCB terminal – S, as
detailed on the interconnection diagram and Figure 10.
•
Fuse F1 located in the terminal box is rated F6.3A HRC for both 100-120V
and 220-240V operation.
WARNING
The sensor head and control unit have independent electrical supplies. This means
that if the sensor head is unpowered, the COe sensor may still be heated to 300°C
by the control unit. If the control unit is unpowered, the sensor head will still be
heated to 250°C by its own power supply.
•
Refer to Appendix A for an interconnecting wiring schedule for the sensor
head. See also the wiring diagrams in Figures 13, 14 and 15.
•
Electrical terminations are suitable for 20 AWG (0.5mm2 ) to 14 AWG
(2.5mm2) solid conductors or 16 AWG (1.5mm2) stranded conductors.
•
Gland entry sizes and positions are shown in Figure 2. Unused entries should
be fitted with appropriate blanking plugs.
•
Ensure that good EMC practices are observed when making connections.
•
All electrical connections and access to the fuse, F1, are made to the terminal
PCB inside of the terminal box enclosure. Refer to Figure 2. To gain access
unscrew the four M6 [11] screws using a 5mm allen key and remove the
terminal box cover. After electrical connections are complete ensure the cover
is fully bolted down.
Table 4 – Sensor head electrical power connections
Terminal
Electrical power
Live
TB1-L
100-120Vac or 220-240Vac
Neutral
TB1-N
50/60Hz, 600VA maximum
Protective earth
TB1-Protective ground
Note that terminal TB1-protective ground is at the right-hand side
Servomex 2700 Installation Manual
31
Figure 10
Sensor head terminal enclosure detail
Key to Figure 10 – Sensor head terminal enclosure detail
1
Terminal block TB5 (combustibles sensor wiring)
Pin 1 at right-hand side
2
Stud terminal – S
3
Terminal block TB3 (oxygen and sensor head temperature wiring)
Pin 1 at right-hand side
4
Fuse F1
5
Terminal block TB1 (main power wiring)
6
Plastic safety cover
7
Terminal block TB9 (mains voltage selection)
Pin 1 at right-hand side
32
Servomex 2700 Installation Manual
CAUTION
After installation, the Sensor Head should not be left on the flue unpowered
for extended periods, as condensation may form within the sample pipe
work. The Sensor Head should be removed from the process and protected
against external contamination, or left with 600ml/min of instrument air
flowing through the calibration port, until the analyser can be fully
commissioned and placed online.
Servomex 2700 Installation Manual
33
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34
Servomex 2700 Installation Manual
4
INSTALLATION OF CONTROL UNIT
4.1
Installation location
Refer to Figure 11.
Servomex 2700 Control Units and air supplies (utilities units) should, ideally, be
mounted within easy reach of one another to aid routine calibration. They should also
be mounted as close as possible to the Sensor Head to minimise the analyser’s
response time to calibration gases, to help maintain the stability of the air supply units
and to minimise the effects of pressure drops.
Select a location which allows convenient access for installation, maintenance and
will minimise ambient temperature fluctuations and vibration. The control unit should
be mounted horizontally with the electrical entries on the under side. The operating
environment conditions for the control unit are in Table 5.
Ensure the ambient temperature does not exceed specification. The control unit and
display may require protection from direct sunlight and local radiant heat sources.
This can be achieved by the installation of a heat shield between the control unit and
the heat source; a thin metal sheet is usually adaquate.
The Servomex 2710 Control Unit is essentially an aluminium enclosure finished with a
protective epoxy powder paint. A polycarbonate window facilitates viewing the
integral display and the user interface is via a polyester keypad. All weatherproof
seals are silicone rubber.
WARNING
If the control unit is to be installed in an area which may be hazardous due to the
presence of flammable gases or dusts then any "Special Conditions for Safe Use"
and/or "Schedules of Limitation", as detailed in the Safety Certification, must be
followed.
NOTES
Allow 365mm at the front and 250mm to the left hand side for service access.
The control unit may be mounted either to a rigid vertical surface (wall mounted)
capable of supporting the weight of the enclosure or panel mounted.
For the wall mounting option two metal mounting brackets are fitted to the rear of the
control unit using four M8 by 20mm screws and washers. Four 12mm diameter holes
are provided for mounting the control unit to the wall. Servomex recommend the use
of M8 or 3/8" bolts to fix the control unit to the wall.
For the panel mounting option the control unit is inserted through the large hole in the
mounting bracket and secured using four M8 by 20mm screws and washers. The size
of the mounting panel is designed to fit standard 19" rack mounting systems. The
mounting panel is provided with eight 6.5mm slots for attachment to the rack or panel.
Servomex 2700 Installation Manual
35
Table 5 – Control unit operating environment
Item
Specification
Ambient operating temperature
-10°C to +55°C (+14°F to +131°F)
Storage temperature
-20°C to +55°C (-4°F to +131°F)
Ingress protection
IP66 and NEMA 4X
AC power supply. Two userselectable voltage ranges:
a) 100-120Vac 50/60Hz
b) 220-240Vac 50/60Hz
a) 100-120Vac -15% +10%
(Min. 85V – Max. 132V)
b) 220-240Vac -15% +10%
(Min. 187V – Max. 264V)
Altitude
Up to 2000m
Installation category
Installation Category II. Local level power
distribution with over-voltage withstand up to
2500V (in accordance with IEC 664).
Pollution degree
Pollution Degree 2 (in accordance with IEC 664 ).
See Note 1
Relative humidity
0 to 80% RH
Note 1: Where the installation is such that the enclosure ingress protection
IP66/Type 4X is maintained and the covers remain securely fitted, the apparatus is
suitable for use in locations where there may be significant deposits of
nonflammable dusts or fibres (Pollution Degree 4) and/or where there may be drips,
splashes of water, prolonged exposure to rain or subjected to hose down.
The covers may be removed during installation or servicing only if there is negligible
risk of pollution or contamination of the electronic circuits contained within the
enclosures and if the covers are securely replaced immediately after the operation
is completed. Refer to Section 6.
36
Servomex 2700 Installation Manual
Figure 11
Control unit installation
180mm
2
260mm
391mm
360mm
1
3
55mm
55mm
55mm
55mm
98mm
71mm
167mm
5
4
51mm
6
127mm
44mm 104mm
7
8
Key to Figure 11 – Control unit installation
1
Keypad and LCD display
2
Door hinge
3
M6 bolts (4 off)
4
3/4" NPT (INT) threaded cable conduit entries or optional adaptors
as required
5
Enclosure breather fitting (optional) or blanking port
6
Wall mounting brackets (optional)
7
EMC earth terminal
8
1/4" NPT (INT) threaded enclosure purge inlet and outlet fittings
(optional) or blanking plugs
Servomex 2700 Installation Manual
37
4.2
Electrical installation
WARNINGS
•
Refer to the warnings and conditions outlined in the "General safety
information" in Section 1.3 of this manual.
•
The sensor head and control unit have independent electrical supplies. This
means that if the sensor head is un-powered, the COe sensor may still be
heated to 300°C by the control unit. If the control unit is un-powered, the
sensor head will still be heated to 250°C by its own power supply.
CAUTION
The control unit is intended to be powered from a supply which has the 'Neutral'
conductor referenced to ground.
Where this is unavailable, it is recommended that a suitable isolating transformer is
installed and the secondary winding is referenced to ground.
The electrical installation must include a fuse (rated as specified in Table 6) in each
supply conductor. The disconnect device (see also Section 1.3) must disconnect
each supply conductor. The fuses must be marked as being associated with this
equipment. Ensure that the installation conforms to the relevant national and local
safety requirements.
NOTES
•
If applicable the conduit or screen associated with the power supply should
be grounded at the cable gland or conduit entry to the control unit enclosure
in accordance with local wiring regulations.
•
The Servomex 2700 is rated in accordance with IEC 644 for INSTALLATION
CATEGORY II which is characterised as being local level (not distribution
level), appliances and portable equipment with over-voltage impulse withstand
up to 2500V.
•
Electrical terminations are suitable for 20 AWG (0.5mm2 ) to 14 AWG
(2.5mm2) solid conductors or 16 AWG (1.5mm2) stranded conductors.
•
Gland entry sizes and positions are shown in Figure 11. Unused entries should
be fitted with appropriate blanking plugs.
•
Do not exceed the maximum load impedance of 1000 ohms for the analogue
(0/4-20mA) current outputs.
38
Servomex 2700 Installation Manual
•
Electrical power should be supplied at 100-120V or 220-240V (+10% -15%)
50/60 Hz. To gain access refer to Figure 11. Unscrew the four M6 bolts [3]
using a 5mm Allen key and open the control unit door. Ensure that the
transformer primary connection (PL6 or PL7 in Figure 12) and the main power
fuse rating (F1) are appropriate for the electrical supply voltage (see Table 6).
Table 6 – Control unit electrical power voltage selection
Nominal voltage
Transformer primary
connection
Mains power fuse (F1)
rating
100-120Vac
PL7
T3.15A HRC
220-240Vac
PL6
T1.6A HRC
•
For compliance with the EMC standards, the control unit enclosure must be
connected to a local EMC earth. Signal cable connections to the control unit
must be made using screened or shielded cable with the screens terminated to
the control unit enclosure. The recommended method is to terminate the
screen or shield at the cable gland. Where this is impractical, the screen or
shield may be terminated inside the enclosure, using the M4 studs adjacent to
the cable entries. Ensure that good EMC practices are observed when making
connections.
•
All electrical connections and access to the mains power fuse, F1, are made to
the control PCB inside of the control unit enclosure. After electrical
connections are complete ensure that the safety cover is re-fitted and the
access door is fully bolted down.
Servomex 2700 Installation Manual
39
Figure 12
Control unit enclosure detail
2
1
4
3
5
6
16
SW2
7
SW3
RV2
15
RV3
8
RV4
14
13
12
11
10
9
1
Key to Figure 12 – Control unit enclosure detail
Tfx sensor coarse zero adjustments SW2 (left) and SW3 (right)
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Sensor heater fuses F2 to F5
Transformer secondary connection PL5
Transformer primary connection PL6 (220-240V nominal)
Transformer primary connection PL7 (100-120V nominal)
Mains power fuse F1
Mains power connections TB3
Relay output connections TB4
(0/4-20mA) Analogue output span adjustment for oxygen sensor RV4
(0/4-20mA) Analogue output span adjustment for combustibles sensor RV3
Terminal block TB2 interconnection wiring and external signal connections
Terminal block TB1 interconnection wiring
M4 cable screen termination studs (4 studs)
Keypad ribbon cable connection PL2
LCD viewing angle adjustment RV2
LCD ribbon cable connection PL1
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Servomex 2700 Installation Manual
Electrical power and user external connections to the analyser outputs are detailed in
Figures 13, 14 and 15 and in Tables 7, 8, 9 and 10. Interconnecting wiring between
the control unit and the sensor head is detailed in Appendix A.
CAUTION
Connections to terminal block TB2-15, 16, 17 and 18 (analogue output signal
terminals) should not exceed 30V RMS (42.4V peak) or 60V dc to earth when
connected to associated equipment.
4.3
Enclosure purge connection
A purge may be applied to the control unit to help prevent corrosion within the
enclosure.
The enclosure purge inlet and outlet connection sizes and location are shown in
Figure 11.
The purge gas must be air from a non-hazardous area source or an inert gas. The
control unit internal volume is approximately 8.5x10-3m3 (520in3). Vent the outlet
freely to atmosphere and ensure that the vent cannot become blocked or restricted.
For hazardous Areas, the purge must satisfy the area safety requirements.
For corrosive purge, a flow rate of 50 to 100ml/min at 50 to 100mm H2O is required.
Servomex 2700 Installation Manual
41
Table 7 – Control unit electrical power connections
Terminal
Electrical power
100 to 120Vac -15% +10%
220 to 240Vac -15% +10%
50/60Hz, 250VA maximum
Live
Neutral
Protective earth
TB3-L
TB3-N
TB3-Protective ground
Note that pin TB3-protective ground is at the top
Table 8 – Relay output connections
Terminal
Relay 1
250Vac, 3A
28V dc, 1A
Closes on relay 1 set and opens on power fail
Opens on relay 1 set and closes on power fail
Common
TB4-1
TB4-2
TB4-3
Relay 2
250Vac, 3A
28V dc, 1A
Closes on relay 2 set and opens on power fail
Opens on relay 2 set and closes on power fail
Common
TB4-4
TB4-5
TB4-6
Relay 3
250Vac, 3A
28V dc, 1A
Closes on relay 3 set and opens on power fail
Opens on relay 3 set and closes on power fail
Common
TB4-7
TB4-8
TB4-9
Relay 4
250Vac, 3A
28V dc, 1A
Closes on relay 4 set and opens on power fail
Opens on relay 4 set and closes on power fail
Common
TB4-10
TB4-11
TB4-12
Note that TB4-12 is at the top
The relay outputs may be configured by the user to be either concentration alarms,
fault indications, autocalibration or blowback valve drives via the analyser software
interface. Minimum 10mA 5V AC or DC. Maximum 3A/250Vac 1A/28Vdc.
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Servomex 2700 Installation Manual
Table 9 – Analogue output connections
Terminal
0/4 to 20mA oxygen output signal (isolated)
maximum load impedance 1000 ohms
+ ve
- ve
TB2-15
TB2-16
0/4 to 20mA combustibles output signal (isolated)
maximum load impedance 1000 ohms
+ ve
- ve
TB2-17
TB2-18
The full scale of the above outputs represents the range selected by the user via
the analyser software interface.
Table 10 – User remote dry contact inputs
Terminal
Close contacts to initiate an automatic calibration of the
analyser
+ ve
ground
TB2-11
TB2-12
Close contacts to initiate an automatic blowback of the
analyser
+ ve
ground
TB2-13
TB2-14
The remote dry contacts must be suitable for use with the low voltage signal
generated by the control unit, i.e. 5V 50µA maximum.
Calibration and blowback parameters to be set by the user via the software
interface prior to remote function initiation.
Servomex 2700 Installation Manual
43
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Servomex 2700 Installation Manual
5
INITIAL STARTUP PROCEDURE
WARNING
Carbon monoxide is a toxic gas. When sampling gases containing carbon monoxide
ensure that adequate precautions are taken to ensure that any vented gases are
suitably extracted.
5.1
Gases required
The gas samples required to commission and calibrate the analyser depend on the
configuration of the analyser. Refer to Table 11.
Table 11 – Gas requirements
Service
Gas
Press.
psig
Flow
l/min
O2
COe
Dual
Aspirator supply
Regulated clean dry air
3-5
typically 1.5
yes
yes
yes
Calibration gas for
O2 'HIGH CAL' and
COe 'LOW CAL'
Regulated clean dry air
0-15
0.6 to 0.8
yes
yes
yes
Calibration gas for
O2 'LOW CAL'
0.3% O2 balance N2 *
0-15
0.6 to 0.8
yes
no
yes
Calibration gas for
COe 'HIGH CAL'
1000ppm(v) CO
balance air **
0-15
0.6 to 0.8
no
yes
yes
*calibration gas composition can be between 0.25% and 2.5% O2 in N2
** calibration gas composition can be between 500ppm(v) to 1,000ppm(v) for a
1750702 sensor and 1,000ppm(v) to 2,000ppm(v) in air for a 1750703 sensor.
Servomex 2700 Installation Manual
45
5.2
Visual inspection
Check the rating label on the sensor head terminal box lid to ensure that the voltage
and frequency stated are suitable for the installation.
In the sensor head terminal box (refer to Figure 10):
•
Check voltage selection link is set to the appropriate supply voltage (see
Section 3.5).
•
Check fuse F1 fitted is F6.3A HRC (voltage independent).
In the control unit (refer to Figure 12):
•
Check that the transformer primary lead is connected to the correct socket.
PL7 for 100V-120V (nominal) or PL6 for 220V-240V (nominal).
•
Check that the fuse F1 fitted is T3.15A HRC for 100-120V (nominal) or
T1.6A HRC for 220-240V (nominal).
Interconnecting wiring:
•
Check that all interconnections are correctly wired and terminated in
accordance with local electrical safety requirements and the interconnection
wiring schedules in Appendix A.
5.3
Initial power up
Connect the sensor head and control units to the nominal required power supply.
Refer to Figure 12. Adjust RV2 on the control unit PCB (viewing angle adjustment for
the LCD display) to give the best display contrast when viewed under normal
conditions.
NOTE
The LCD display may appear completely blank if this control is incorrectly adjusted.
From a cold start, the sensor head will pre-heat the air space, depending on
configuration and ambient temperature before applying power to the individual sensor
heaters. The aspirator air supply is controlled by a solenoid valve. The solenoid valve
will remain closed until the sensor head is at operating temperature. This will prevent
inadvertent damage to the sensor head by exposing it to sample gases before the
internal temperature is above the sample gas dew point. The solenoid valve will
operate after a time interval of between 15 and 60 minutes depending on
configuration and ambient temperature.
46
Servomex 2700 Installation Manual
Wait until both the sensor head and control unit have both been switched on for a
minimum of 90 minutes. Refer to Figure 11 and perform the following tests.
•
Using the control unit keypad select the VIEW menu entry then scroll using the
up and down arrow keys until the oxygen sensor temperature is displayed.
Check that the oxygen sensor temperature is stable at 700° ±10°C.
•
Scroll the display using the up and down arrow keys until the combustibles
sensor temperature is displayed. Check that the combustibles sensor
temperature is stable at 300° ±10°C.
5.4
Analogue output span setup
Refer to the Servomex 2700 QuickStart manual .
•
If a zirconia sensor is fitted then select the SET OUTPUTS option in the
SERVICE menu and select 20mA for the oxygen analogue output. Check the
current at TB2/15 & 16 in the control unit is 20.00 ±0.01mA; if necessary,
adjust RV4 on the control unit PCB until the analogue output reads
20.00 ±0.01mA.
•
If a combustibles sensor is fitted then select the SET OUTPUTS option in the
SERVICE menu and select 20mA for the combustibles output. Check the
current at TB2/17 & 18 in the control unit is 20.00 ±0.01mA; if necessary,
adjust RV3 on the control unit PCB until the analogue output reads
20.00 ±0.01mA.
5.5
Sensor head sample flow adjustment
With the 2700 analyser powered and the sensor head at a stable temperature, adjust
the aspirator air supply pressure so that the value indicated on the label in the sensor
head terminal enclosure is achieved at the sensor head. This produces a sample flow
of 200 to 300 ml/min. Allowance should be made for pressure loss between the
indicator and the sensor head where necessary.
5.6
Combustibles sensor zero adjustment
If a combustibles sensor is fitted then refer to Figure 12 and perform the following
check and adjustments, if necessary:
•
Apply an air sample to the calibration gas inlet at 600 to 800ml/min flow rate
for at least 5 minutes.
•
Using the keypad select the VIEW menu entry and scroll using up and down
arrow keys to select the combustibles sensor output voltage.
•
Check that the sensor output voltage is less than 60mV (positive or negative).
If not, check the installation wiring.
Servomex 2700 Installation Manual
47
•
If the installation appears correct, set SW2 on the control PCB to the zero
position. If the voltage measured is positive, set SW3 to the lower position
(towards the bottom of the unit). If the voltage measured is negative, set SW3
to the upper position (towards the top of the unit).
•
Adjust SW2 clockwise one step at a time, until the sensor voltage is less than
60mV (positive or negative). Note there will be a lag of up to 30 seconds
between a switch change and the voltage response.
5.7
Sensor calibration
The sensor head must be powered and at a stable temperature for a minimum of 24
hours.
Refer to the Servomex 2700 QuickStart manual.
•
Apply an air sample to the calibration gas inlet at a flow rate of 600 to
800ml/min. Perform a HIGH point calibration of the zirconia sensor (if fitted)
and a LOW point calibration of the combustibles sensor (if fitted).
•
Apply a nominal 0.3% O2 in N2 gas mixture to the calibration gas inlet at a flow
rate of 600 to 800ml/min. Perform a LOW point calibration of the zirconia
sensor (if fitted). Verify that the analyser display reads the correct gas
concentration, as set in the calibration procedure.
•
Apply a nominal 1000ppm(v) CO in air gas mixture to the calibration gas inlet
at a flow rate of 600 to 800ml/min. Perform a HIGH point calibration of the
combustibles sensor (if fitted). Verify that the analyser display reads the
correct gas concentration, as set in the calibration procedure.
NOTE
After inital startup and calibration it is recommended that the calibration, catchpots
and air filter are checked within the 5 to 10 days.
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Servomex 2700 Installation Manual
6
MAINTENANCE AND SERVICING
This section refers to installation of the analyser. For technical descriptions, fault
diagnosis information, parts removal, refitting and test instructions, tool and test
equipment lists, a Service Manual is available for use by qualified personnel, part
number 02700002C.
OPENING COVERS
The covers may only be opened during installation or servicing if there is negligible
risk of pollution of the electronic circuits due to moisture, liquids, dirt, dust or other
form of contamination.
Before refitting the covers, ensure the sealing gasket is clean, dry and undamaged.
All covers should be replaced and secured as soon as possible after completing the
operation.
CLEANING
In order to avoid dirt or water entering the enclosures when the covers are opened,
the external surfaces of the analyser should be clean and dry before any cover is
opened. Remove dust and loose particles with a soft brush. Wipe the surfaces
thoroughly with a clean cloth, moistened with water. CAUTION... the sensor head
may be hot.
It is recommended that the analyser should have its calibration checked once a
month, and catch pots and air filters should be checked every three months. These
times can then be adjusted depending on site experience.
Analyser flow rates, air supplies, probes and filters (internal an external), should be
checked once per year, as well as the whole analyser and cabling for signs of wear.
In more rugged applications, these times may need to be shorter, depending on
experience.
Servomex 2700 Installation Manual
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50
Servomex 2700 Installation Manual
Appendix A
INTERCONNECTING WIRING SCHEDULES
The interconnecting wiring specification is given in Table 12. Wiring schedules for the
oxygen only, the combustibles only and the dual sensor versions are given in
Tables 13, 14 and 15 accordingly.
The electrical terminations in the Servomex 2700 are suitable for 20AWG (0.5mm2) to
14AWG (2.5mm2) solid and 16AWG (1.5mm2) stranded conductors. Both the Control
Unit and Sensor Head have independent AC power supplies.
The maximum loop resistance limit of 4 ohms is required only for the sensor heater
lines (2 lines per sensor). The sensor outputs, temperature signals and bridge supply
wires need not be limited by this restriction on resistance. Depending on installation
environment it may prove more cost effective to use interconnecting cables with more
twisted pairs but with a smaller cross section per core and where necessary to run
heater wires in parallel to produce the required minimum loop resistance of 4 ohms.
Table 12 – Interconnecting cable requirements
1.0mm2
1.5mm2
2.5mm2
Oxygen only
3 twisted pairs with overall screen.
Minimum 0.5mm2 cross section.
Maximum heater loop resistance 4 ohms.
Combustibles
only
6 twisted pairs individually screened and overall screened. 100m
Minimum 0.5mm2 cross section.
max.
Maximum heater loop resistance 4 ohms.
Oxygen and
combustibles
See Note 2
Minimum 9 twisted pairs individually screened and overall 100m
screened. 0.5mm2 cross section.
max.
Maximum heater loop resistance 4 ohms.
100m
150m
300m
Note 1: For optional sensor head temperature display and the sensor head
temperature high and sensor head temperature low faults at control unit,
add 1 extra twisted pair to cable specification.
Note 2: Recommend 12 twisted pairs, individually screened and overall screened
0.5mm2 cross section conductors. Use 2 pairs for the Ziconia sensor
heater. Cable and gland sizes may vary depending on the manufacturer.
Always check that the outside diameter of the cable is suitable for the gland
being specified.
Recommended Cables and Suppliers (Always check manufactures specification for full
compatibility before use).
Analyser
Oxygen Only
Combustibles Only
Oxygen and Combustibles
Cable Supplier
Alpha……………………………………
Belden…………………………………..
Alpha……………………………………
Belden…………………………………..
Alpha……………………………………
Belden…………………………………..
Servomex 2700 Installation Manual
Part Number
5610B2004
1056A
5620B2008
1077A
5620B2012
1078A
51
Figure 13
52
Oxygen sensor only interconnection wiring schematic
Servomex 2700 Installation Manual
Table 13 – Oxygen sensor only interconnecting wiring
Sensor
head
terminal
TB3-1
TB3-2
TB3-3
Function
Optional sensor head temperature
measurement
+ve
TB1-9
-ve
TB1-10
Zirconia cell output
-ve
TB1-7
+ve
TB1-8
TB3-4
TB3-5
Control
unit
terminal
Zirconia sensor heater supply (polarity not important)
TB3-6
TB3-7
TB2-8
Zirconia sensor temperature output
TB3-8
TB3-9
TB2-7
+ve
TB2-9
-ve
TB2-10
Overall cable screen connection *
Enclosure
* for correct earthing details see Section 4.2
Servomex 2700 Installation Manual
53
Figure 14
54
Combustibles only interconnection wiring schematic
Servomex 2700 Installation Manual
Table 14 – Combustibles only interconnecting wiring
Sensor
head
terminal
TB5-1
TB5-2
TB5-3
Function
Control
unit
terminal
Combustibles sensor heater supply (polarity not
important)
TB2-2
sense
TB2-5
TB5-4
-ve
TB2-4
TB5-5
+ve
TB2-3
+ve
TB1-1
-ve
TB1-6
+ve
TB1-3
-ve
TB1-2
+ve
TB1-4
-ve
TB1-5
ground
TB2-6
TB5-6
Combustibles sensor temperature output
TB2-1
Combustibles sensor bridge supply
TB5-7
TB5-8
Combustibles sensor bridge output
TB5-9
TB5-10
TB5-11
TB5-12
Stud
terminal 'S’
TB5-13
Combustibles sensor bridge offset
correction
Combustibles sensor temperature output
Individual screens and unused cores
Enclosure
Overall cable screen connection *
Enclosure
* for correct earthing details see Section 4.2
Servomex 2700 Installation Manual
55
Figure 15
56
Dual sensor interconnection wiring schematic
Servomex 2700 Installation Manual
Table 15 – Dual sensor interconnecting wiring
Sensor
head
terminal
TB5-1
TB5-2
TB5-3
Function
Control
unit
terminal
Combustibles sensor heater supply (polarity not
important)
TB2-2
sense
TB2-5
TB5-4
-ve
TB2-4
TB5-5
+ve
TB2-3
+ve
TB1-1
-ve
TB1-6
+ve
TB1-3
-ve
TB1-2
+ve
TB1-4
-ve
TB1-5
ground
TB2-6
TB5-6
Combustibles sensor temperature output
TB2-1
Combustibles sensor bridge supply
TB5-7
TB5-8
Combustibles sensor bridge output
TB5-9
TB5-10
TB5-11
Combustibles sensor bridge offset
correction
TB5-12
Combustibles sensor temperature output
TB5-13
Overall cable screen connection *
TB3-1
Optional sensor head temperature
measurement
+ve
TB1-9
-ve
TB1-10
Zirconia cell output
-ve
TB1-7
+ve
TB1-8
TB3-2
TB3-3
TB3-4
TB3-5
Enclosure
Zirconia sensor heater supply (polarity not important)
TB3-6
TB3-7
TB2-8
Zirconia sensor temperature output
TB3-8
Stud
terminal 'S’
TB2-7
+ve
TB2-9
-ve
TB2-10
Individual screens and unused cores
Enclosure
* for correct earthing details see Section 4.2
Servomex 2700 Installation Manual
57
NOTES
58
Servomex 2700 Installation Manual